Ornamental molded article and method of making the same



mm Jan. 7, 1930 UNITED STATES PATENT OFFICE RABBI PARKER KILLS, OI TORONTO, ONTARIO, CANADA, ASSIGNOR 'IO BAKELITE CORPORATION, 01' NEW YORK, N. Y., A CORPORATION 01 DELAWARE OBNAIENTAL MOLDED ARTICLE AND METHOD O1 MAKING THE SAME Ilo Drawing. Application filed September 29, 1925, Serial No. 59,422. Renewed April 1, 1929.

This invention relates to molded articles carrying on their surface letters, symbols, desi or ornamentation of any kind, all of which will for convenience be referred to 5 simply as designs. A typical article of this 1s a radio panel, usually comprising a multiplicity of paper sheets, impregnated with a reactive phenol resin and consolidated by hotress molding: such panels are often require to bear designs as mentioned above,

such for example as letters in white or old. Or in certain cases the entire surface 0 the panel is ornamented in imitation of natural woods, etc.

In all such cases so far as I am aware, the distinctive color which marks the design has been applied to the individual molded article, rendering necessary a separate treatment of each article after 1t leaves the mold; or in case of such surface ornamentation as is last above mentioned, the color design is printed on a sheet, usually of paper, which is thereafter coated or impregnated with the phenolic resin and consolidated with the other sheets by the hot-press molding operation, the ornamented sheet in such case constituting the outermost sheet of the laminated article, or in some cases being even overlaid b an additional transparent or translucent eet.

In all such cases the brilliance and purity of the color is of course lost in part, being obscured by the overlying fihn of varnish.

According to the present invention I am enabled to avoid both of the foregoing difficulties, and to produce directly from the mold a finished article which bears the design in any desired color, and of which the brilllance is not obscured by an overlying varnish film. I may accomplish this result in several different ways according to the particular result desired. The following will serve as illustrations of methods in accordance with my invention, although it is to be clearly understood that the invention is not limited to the particular mani ulations described:

1. The face 0 the mold, or in the case of laminated stock the burnished late of co per or other metal against whic the stoc is d, is engraved in accordance with the desired design. The lines in the mold or metal sheet are then filled with a molding mixture comprising a reactive phenol resin and whatever coloring matter may be desired, such as gilt, bronze, or other metal powder or the like. The engraved copper plate or other die containing this molding mixture is then pressed against the laminated stock to which thedesign is to be transferred. If this stock is wholly uncured it contains fusible material which causes the lines to blur, since it allows some flow. Accordin 1y I prefer to partially cure the backing unti it reaches a condition where there is no longer sufficient flow to cause blurring, although suflicient plasticity is retained to insure integral union of the design with the base. die having its lines filled with molding mixture is then pressed against it in the usual manner and the result is a raised design or lettering on the backin integral therewith, and corresponding to t e engraving on the plate. The curing is completed to the extent desired by sufiicient application of heat durlng thls pressing operation.

2. The same result may be accomplished by The engraved plate or the copper sheet. This printin may be one with a reactive phenol resin mo din mixture or ink similar to that described a ove, and the copper may then be applied to the partially cured backing in the same manner.

3. The letterlng or design ma be printed upon an already impregnated fi brous sheet, with the same type of reactive phenol resin molding mix or ink. Tliis sheet ma be partiall cured before the rinting i desired. t is then backed and pressed in the usual manner.

Highly colored reactive phenol resin molding mixtures, or inks, of the type herein referred to, ma be prepared b mixing metal powder or 0t er suitably colored substance with suflicient reactive resin to form a binder.

By the method of applyin a design or lettering which I have descri d clearer and more attractive colors and desi effects are obtained. This is important w ere a design comprising very fine hnes is desired, or where it is necessary to produce a predetermined shade of color, since even the most trans tioncomprising a pi parent resin will artially obscure the des gn and darken the co or efiect.

I claim:

1. ,An article for cured, substantially non-flowin slightly astic condition having upon t e surface t ereof a raised design composed of a distinctively-colored potentially reactive phenol resin composition in a substantially unreacted state.

2. Process of making molded articles having on the surface thereof an integral raised desi in distinctive colors and free from over ying films comprisin filling depressed lines or areas of a suitable 'e with a composient and a reactive phenol resin, transferring said composition to a phenol resin composition in state, and simultaneously furt er curing the composition, whereby integral union is secured without blurring. y

In testimon whereof, I aflix my si ature.

- RRY PARKER MfI iLs.

plartially cured use the molding art, comprising a sheet of reactive phenol resin compositionin partially 

